Plasma stream apparatus and methods



Jan. 26, 1960 a. M. GlANNlNl ETAL 2,922,869

PLASMA STREAM APPARATUS AND METHODS Original Filed Nov. 18, 1957 8 Sheets-Sheet 3 FIG. 5. /57

Jan. 26, 1960 G. M. GIANNI'NI ETAL 2,922,869

PLASMA STREAM APPARATUS AND METHODS Original Filed Nov. 18, 1957 8 Sheets-Sheet 4 6 t G 1934/: F: r .1 T W. W EAL K 4 2 .t 5 Q/ m U M 5 W i w M FIG. 7.

M M a m INVENTORS Jan. 26, 1960 G. M. GlANNlNl ETAL 2,922,869

PLASMA STREAM APPARATUS AND METHODS Original Filed Nov. 18, 1957 8 Sheets-Sheet 7 Pia. 25.

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59 555 V F r 6% gig M722 1 572 55 35; 2

12! I 56 :7! o 'WW' 9 25 564 am i 5 BY MW POWDER 4N0 64$ 47702/VE y Jan. 26, 1960 G. M. GIANNINI ETAL 2,922,869

PLASMA STREAM APPARATUS AND METHODS Original Filed Nov. 18, 1957 8 Sheets-Sheet 8 .FT ZG. Z8.

sssJ A a9 UH ||||l INVENTORS @4505; 4/. G/fi/V/W/V/ 76m 500. gaewA a c. aucpr/ United States Patent 2,921,869 PLASMA. STREAM APPARATUS AND METHODS Gabriel M. Giannini, Newport Beach, and Adriano C.

Ducati, Corona Del Mar, Califl, assignors to Plasmadyne Corporation, Santa Ana, Calif., a corporation of California Continuation of application Serial No. 697,279, November 18, 1957. This application July 7, 1958, Serial No. 747,094

49 Claims. (Cl. 219-75) This invention relates to plasma stream apparatus and methods, and more particularly to plasma stream torches, methods of creating and sustaining very high-temperature plasma streams or jets, and methods of using the same. The present application is a continuation of our co-pending application Serial No. 697,279, filed November 18, 1957, for Plasma Stream Apparatus and Methods. Said application is a continuation-in-part of our application Serial No- 649,461, filed March 29, 1957, under the same title, both now abandoned.

Streams of plasma (which has been defined as consisting of neutral gas, ions and electrons, at high temperatures) have been observed as physical phenomena for many years, for example in connection with electric arcs. Such streams have been employed to achieve very high temperatures for short periods of time. All known prior art activity in the very high-temperature field has, however, been theoretical in nature and has not been productive of practical apparatus and methods capable of commercial use in arts such as cutting, welding, meta1 izing, ceramic coating, surface treating, sintering, etc.

An important field of activity to which the present application is directed is the field of workpiece heating, especially localized heating, now occupied largely by gas equipment and electric arc and other devices. Electric furnaces now operate in a relatively high-temperature range, up to about 10,000 E, as do solar furnaces and certain special cutting flames such as the oxy-aluminum and Thermit flames. The high current-density torch of the present invention, however, provides sustained pure heat and much higher temperatures. The present torch normally operates in the general range of 5,0[)0 F. to 30,000" F., and at atmospheric (or other) pressures. The upper portions of this temperature range, above 10,000 E, may be termed, for purposes of the present patent application, the very high temperature range. Such terminology is employed despite an appreciation of the fact that much higher temperatures are present in certain instantaneous reactions, such as atomic explosions.

In addition to temperature limitations, conventional gas and are apparatus is subject to many other limitations and defects well known to the art. For example, in con nection with conventional are devices it is necessary that the work be made a component of the electrical circuitwhich eliminates this method of heating when the work is not electrically conductive. Furthermore, and very importantly, the necessity of connecting the work in the electrical circuit gives rise to numerous problems of current connection, mobility, and the like. In addition, the necessity of connecting the work in circuit makes it impractical or impossible to effect simultaneous cutting of a plate by the use of two are devices disposed on opposite sides of the plate. The simultaneous cutting of a plate from both sides thereof is important not only in connection with cutting speed, but in connection with preventing formation of undesirable ridges along one side of the plate being cut.

Other limitations and problems with relation to conherein.

ventional heating apparatus, especially as to temperature, are so numerous that it is impractical to specify them Some such problems, and their solutions with the apparatus and methods of the present invention, will, however, be set forth in subsequent portions of this specification.

In view of the above and other factors characteristic of conventional heating and related equipment, it is an object of the present invention to provide practical, commercial plasma stream apparatus and methods which are not subject to the above-specified, and other, limitations and defects.

Another object is to provide apparatus and methods for the electrical circuit, and in which temperatures are produced which are greatly higher than those produced with conventional gas or are equipment.

An additional object is to provide a practical and useful plasma stream torch for creating and maintaining very high temperatures, which torch has metal electrodes and will operate for relatively long periods without the necessity for replacement of parts and without loss of desirable operating characteristics.

Another object is to provide novel means and methods for protecting and cooling the electrodes of a very hightemperature plasma stream torch, to prevent such electrodes from burning or deteriorating in a short time, and to result in a long-lasting torch which is practical and useful in construction and operation.

A further object is to provide novel means and methods for injecting substances into plasma streams.

Another object is to provide novel means and methods for constricting an electric arc in a plasma stream apparatus.

A further object is to provide apparatus and methods for producing a whirling or vertical flow of gas in a plasma stream torch in order to constrict the electric arc, and also to electrically insulate portions of the torch, protect such portions from deterioration, and efiect protection of work being operated upon by the torch.

A further object is to produce high-density plasma streams with electrodes having a novel electrical polarity, such plasma streams having improved characteristics including greatly elevated temperatures as compared to prior art plasma streams.

A further object is to provide novel nozzle structures for plasma stream torches.

Another object is to provide means and methods for providing fluid cooling of the components of the plasma stream apparatus, and for producing the maximum cooling efiectwithout placing fluid seals undesirably near the plasma stream.

An additional object is to provide means and methods for preventing power losses and other undesirable elfects within a plasma jet torch, such effects resulting from undesired electrical discharges between portions of the electrodes.

A further object is to provide novel interchangeable electrodes for plasma stream torches.

An additional object comprises the provision of means and methods for cooling the periphery of the torch and both electrodes thereof with but one set of intake and return coolant conduits, and without resulting in electrolysis, power losses or other undesired effects.

An additional object is to prevent starting of an electric are on the inside (relatively adjacent the back electrode or plate) of the'opening in the nozzle electrode,

and to protect such nozzle from oxidation and excessive deterioration. 1 4 v Another object comprises the provision of apparatus and methods for feeding large amounts of current tothe electrodes of plasma stream apparatus in a radial An additional object is to provide a methodjof controlling the length and characteristics of a plasma jet by regulating gas flow in the nozzle electrode.

Other objects include the provision of novel methods of ceramic spraying or metalizing metals and nonmetals,-

welding metals and non-metals with the work-not in cir cuit, cutting and drilling metals and non-metals with thework not in circuit, quick heating of metals and non: metals, localized and other hardening of metals, surface treating of metals and non-metals, sintering, shaping, ore refining, etc.

These and other objects and advantages of the invention will be more fully set forth in the following speci-' fication and claims, considered inconnection with at-- tached drawings to which they relate.

. In the drawings: t

' Figure 1 is a view illustrating one form of-plasma stream torch, constructed in accordance with the present inventionfas associated with control and supply elements. which are shown schematically; a I c Figure 2 is an enlarged longitudinalcentral sectional view' of-the torchytaken on line 22 of Figure 1;

Figure 2A isa transverse view, half in section and halfin end elevation, on the broken line ZA-ZA ofvFigure 2;

Figure 20 is a schematic longitudinal central sectional view illustrating another formof interchangeable elec-" trode, characterized by centrifugal or vortical fluid cooling of the nozzle;

Figure 23 is a schematic longitudinal central sectional view illustrating formation of the arc passage or chamber with both gas and water; I

Figure 24 corresponds somewhat to Figure 23, but -1llustrates the use of a wallor divider between the gas and water;

Figure 25 illustrates, in schematicform, a method of coating a workpiece with a substance such as ceramic,

such substance being introduced intothe gas which con:

stricts the arc and'insulates and protects the nozzle;

Figure 26 correspon-ds somewhat to Figure 25, but

illustrates the introduction of a substance through a hole the coating substance being introduced into the end of i the plasma; stream or jet in theform of a rod or wire;

Figure 2B is a fragmentary longitudinal sectional view Y on line 2B-2B of Figure 2A;

Figure 3 is a longitudinal central sectional view ofa second and more commercially practical plasma stream torch, constructed in accordance with the present invention; i

Figure 4 is a section on line 4-4 of Figure 3;

Figure 5 is a schematic view, in longitudinal central section, illustrating basic components of a plasma stream torch, and indicating the electrical polarity which is pref erably employed in the torch;

Figure 6 is a schematic view corresponding generally to Figure 5, but illustrating the flattened electrodes per mitting radial fiow of current to or from the arcing points or regions;

Figure 7 illustrates in schematic form a basic means for effecting cooling of the electrodes of the torchfto provide the maximum cooling effect near the arcing-portions of the nozzle and plate;

Figure 8 is a schematic view, in longitudinal central section, illustrating means for dynamically constricting the arc and for protecting, cooling and electrically insulating portions of the electrodes of a plasma stream torch; 7

Figures 8A, 8B, 8C and 8D are schematic viewsil lustrating nozzle-arc relationships with different electrical polarities and gas new conditions; 1

Figure 9 is a schematic view illustrating cooling not only of the electrodes but also of the casing of the torch;

Figure 10 is a schematic view which is generally similar to Figure 9, but which illustrates the provision of additional gas, flow means in order to aid in protection of the work from oxidation, and in order to permit introduction of substances into the plasma stream at a point outside the arc'chamber; j I

Figures ll-19 are fragmentary longitudinal central sectional views illustrating various forms of nozzle and plate electrodes, and various means for protecting: the same with electrically-conductive refractory substances;

Figure 28 illustrates-an additional methodof coatingormetalizihg by use of the plasma stream torch, the coating substance being introduced externally of the torch and in particulate form;

Figure 29 illustrates a method of shaping a workpiece with the very high-temperature plasma stream torch;

. Figure 30 illustrates the use of the torch in hole punching, cutting and the like;

Figure 30A illustrates cutting of a plate simultaneously from opposite sidje'sthereof; I I I e Figure 31 illustrates a method'of welding with the torch; and p Figure 32 illustrates the use of the torch in-surface treating,'sintering, etc. e

In the following specification there will first be described, in non-schematic form and for purposes of illustration and orientation, several embodiments (Figures M) of plasma jet torches constructed inraccordance with the present invention. Much of the theory and methods with relation to such very high-temperature torches will then be described, and with particular reference to schematic Figures 5-10. Thereafter, a number of forms of electrode structures will be described with reference to schematic Figures 11-19, and additional embodiments will be described with reference to the schematic showings of Figures20-24. Methods of employing the torches are illustrated schematically in Figures 25-32, and will be described in connection therewith.

Referring first to Figures 1, 2, 2A and, 2B, the very high-temperature plasma stream torch is indicated generally at 1, and is illustrated to comprise a body 2, a handle 3, a plate or base (back) electrode 4, a nozzle electrode 6, and a cap 7. i

Body 2, which is formed with a good electrical conductor such as copper, has-outer and inner tube portions ,8 and 9, respectively, which are integrally con nected 'at their'upper ends'(Figure 2).- Outer tube portion 8 is threaded to receive the upper end'of the handle 3, which is-formed of a suitable insulating material. The "extreme upper end of the body '2, where the outer and inner tube portions 8 and9 are connected, is formed as a radial surface 11 surrounding an upstandingneclc 12.

Theplateor base electrode 4, also formed of a good electrical conductor'such as copper, comprises -'a hollow disc having an upper wall 13 and a lower wall 14, the latter being open' at its center so'that it mayJfit-closely around neck 12. Lower wall 14 seats on radial sur- {ace 11 of body 2 to provide good electrical contact therebetween. Current flowing from the body into wall 14 will therefo're flow through the side or peripheral wall 16 of plate 4, and thus to the periphery of upper Wall 13 and radially inwardly to the central or arcing portion thereof. I

The central part of upper plate wall 13 is formed with an integral, downwardly extending tube or stem portion 17 which seats at its lower end on the upper end of a tube 18. Tube 18, in turn, is held by a web 19 in body portion 9, and by the lower closed end 21 of portion 9, in position along the axis of the body. It follows that material flowing through tube 18 will pass into and through the central hole or passage 22 in tube portion 17 and upper plate wall 13 for discharge into the base of the plasma stream as will be described hereinafter. 1

The nozzle electrode 6 is illustrated in Figure 2 to comprise a single piece of metal, again a good electrical conductor such as copper, having a cylindrical side Wall 23 connected at its upper end to a radial, inwardly extending wall or disc 24. Walls 23 and 24 are both hollow and form a water chamber 26, the latter being sealed at the lower end of side wall 23 by a disc or gasket 27 formed of a suitable sealing and electrical insulating material. Formed at the center of radial wall 24 is an annular nozzle wall 28 which closes the adjacent portion of water chamber 26, and which defines the nozzle opening for the plasma jet or stream.

' The shape and function of nozzle wall 28, and the electrically conductive refractory substance 29 thereon, will be described subsequently (particularly in connection with Figures 8 and 17). Similarly, the electrically conductive refractory substance 31 which is inset in the upper wall 13 of plate electrode 4 will be described in connection with Figure 19, such substance and the surrounding region of wall 13 being exposed to the electrode 6 by providing a relatively large opening 32 in the center of insulating disc 27.

The cap 7 is shaped somewhat similarly to nozzle electrode 6, having a cylindrical side wall 33 and a radially inwardly extending upper wall 34. The cap is also formed of copper or other electrical conductor, and nests closely over the nozzle to provide good electrical contact therewith. The lower end of side wall 33 is threaded over the upper end of an insulating sleeve 36 which surrounds plate side wall 16 and is itself threaded 'over the upper end of body 2. The construction is thus such that threading of the cap into sleeve 36, and threading of the sleeve onto body 2, produces drawing of the nozzle electrode 6 downwardly onto insulating disc 27. This, in turn, presses plate 4 downwardly onto surface 11 to provide close contact between the elements.

There will next be given a brief, preliminary description of the gas, coolant and electrical means and circuits, and of the'mode of operation of the torch. A suitable source of electrical power (preferably a direct eurrent source) is indicated at 37 in Figure l, and is connected by means of leads 38 to a combination electrical and gas control means 39. The positive terminal of control 39 is connected through a positive lead 41 and a connector 42 to a threaded post 43 on body 2. Current thus flows into the body 2 and, as previously stated, into the central portion'of upper plate wall 13. The current thenflows in an electric arc from the refractoryfsubstance 31. (around opening 22) to the outer orupper portion of the refractory substance 29, as will be described in detail subsequently. The remaining portion of the electrical circuit includes nozzle electrode 6 and its -abutting cap 7, a threaded post 44 on the cap, and a negative lead 46 to the negative terminal of control 39.

The are which flows between the nozzle and plate electrodes may be struck in a conventional manner, such as byinserting a thin stick of graphite therebetween, or

by momentarily impressing a high frequency voltage thereon.

The electric arc is constricted, as will be described, by gas which flows into the arc chamber and then expands outwardly through the narrow or minimum-diameter opening 47 in the nozzle, which constriction results in a high current density with consequent formation of a very high-temperature plasmajet or stream indicated at 48. This stream extends outwardly through the nozzle opening, and through a central opening 49 in cap wall 34, to provide the various useful heating effects which will be described hereinafter.

Cooling means, for maintaining the metal electrodes 4 and 6 relatively cool despite the tremendous heat generated in the arc and in the plasma stream, are illus trated to comprise a suitable source 51 of water or other coolant fluid. Source 51 is connected through an intake hose 52 to the lower end of the annulus 53 between tube 18 and tube portion 9 of the torch body. The water flows upwardly through annulus 53 and around tube portion 17, where it impinges against the lower surface of upper electrode wall 13 relatively adjacent refractory substance 31 from which the plasma stream emanates. The water then flows over the rim of neck 12 and into the hollow center portion of the electrode disc 4, after which it flows downwardly through an opening 54 in lower wall 14 and into an annular groove 56 in radial surface 11. Suitable O-rings 57-59 are provided to prevent leakage of water out of the above-described passages and chamber.

From groove 56, the water flows downwardly through a passage 61 in body 2 and thence into a hose 62 which is formed of an insulating material such as rubber. Hose 62 extends upwardly (Figure 2) to cap 7, so that the water may flow into a first semi-annular recess 63 which is provided in cap side wall 33 adjacent the outermost surface of electrode side wall 23. Recess 63 is separated from a corresponding semi-annular recess 64 by lands, not shown. The water in recess 63 flows through an opening 66 in the outer side wall 23 of electrode 6, and thence through the water chamber 26 for discharge throughan opening 67 into recess 64. The Water then flows through an outlet or return conduit 68 back to the water source 51 or to a suitable drain. The water in 'cap recesses 63 and 64 provides cooling of the cap, and the water in water chamber 26 provides cooling of the nozzle electrode 6, all as will be described in detail subsequently.

A source of gas is indicated at 69 in Figure l, and is connected by a conduit 71 to' the control 39. From coritrol 39, the gas flows through a conduit 72 to the upper portion of cap 7 and into a passage 73 therein. Passage 73 (Figure 2A) is perfectly tangential to a cylindrical chamber or recess'74 which is formed in cap wall 34 and is partially closed, on its lower side, by the upper surface of electrode wall 24. t The passage 73 terminates in a tangential opening 76, so that gases entering the chamber 74 follow a whirling or vortical path. The central portion of the whirling gases in chamber 74 flow outwardly along a curved lip 77 around opening 49, and thus outwardly around the plasma jet 48 to produce protective and other actions.

Passage 73 intersects and communicates with an annular channel 78 which is formed in wall 34 radially outwardly of chamber 74. Channel 78 communicates, through a tube 79 which is sealin gly extended between the outer and inner components of electrode side wall 23, with a passage 81 which is tangential to the cylindrical gas or nozzle chamber 82 defined by the electrodes 4 and 6. Passage 81 enters the chamber 82 through a tangential opening 83 located closely adjacent the lower surface of wall 24. Whirling or vortical gases are thus introduced into the chamber 82, and flow (at the center or vortex) around the plasma stream 48 and upwardly through the opening 47 to provide arc constriction as which-will be describedindetailhereinafter (particularv ly. with reference to Figure- 8)] It is pointed out that no ;O-r1ngs-need'be providedsealthe annularchannel 7 8 since'any gas"leakage--willmerely" enter chamber 74.- O-rings 84 are,-however,-provided on bothsides of recesses 63 and 64 td-preven-t-leak age of water-therefrom; I j

Referring again to-Figure 1, a source =86 -of auxiliary substance (normally gas or-powder) is shown-asbeing connected through a conduit 87 to the lower end of tube 18 (Figure 2). The substance from ,source86 flows through the conduit 87 and tube 18-into and throughthec'entral hole or passage 22in-tube portion 17 andupper plate wall 13. In-this manner, auxiliary materials are introduced into the baseof plasma stream 48 -to provide various effects and functions-aswill be set forth subsequently.

Embodiment 'of Figures 3 CW4 Referring to Figuresj3- and 4, an embodiment is illustrated which is morecommercially practical for m'ostpurposes, and moreeconomical to manufacture and operate, than the one previouslydescribed. In this-embodiment', the body has been given the reference numeral88, the plate electrode-has been designated 89, the=nozzle 91 and the cap 92. Body 88 comprises'a cylinder 93 having an integral radial flange 94 at its upperend, and -is formed of a good conductor such" as copper; Acylindrical recess 96-is provided in the upper end ofbody 88 in order to receive cooling water for the plate electrode 89, such water circulating through first and second passages 97 and 98 formed longitudinally of cylinder 93 but offset from the center thereof. A third passage-99 is formed axially in cylinder 93, being provided at its upper end with a counterbore 101 which receives a stem or tube portion 102'formed'axially of plate 89. Suitable O-rings 103 and 104 are provided; respectively, around stem 102 and radially outwardly of recess 96 in order to seal off the water in recess 96*as well as the material in axial passage 99.

Plate or base electrode 89cornprises a disc of copper, or other suitable-conductor, having a central opening 106 which communicates through stern 102 withpassage 99. An electrically-conductiverefractorysubstance 107 isprovided around opening- 106 to retarddeterioration thereof as will be described subsequently. At its upper, outer;portion the plate disc is annularly recessed to rec eivein flush relationship an insulating ring or gasket 108. Such ring projects farther outwardly than the disc so that it may-seatover the upper edge of an additional insulating element 109 which fits closely around and conforms to the exteriorq surface of body 88 and also of plate 89.

Nozzle electrode 91-is also formed of a good electrical conductor such as copper, and comprises a solid annular portion lll having a depending" cylindrical skirt 112 which fits closely around the outersurface of insulating element 109. Formed integral with the upper end of portion 111 is an inwardly extending wall or disc 113which is made hollow to provide a water chamber 114. A short cylinder 116 is suitably brazed, at 117 and 118, around the wall 113 in order to close-the water chamber 114.--

Wall 113, at its axis orcenter, is formedwith a cylindrical passage or opening 119 adapted to receive the tubular body 121 of an electrically conductive insert formed of copper or the'like. A radial flange 122, provided at the upperend ofbodyv 121, seats over the upper surface of wall-113. The insert body 121 is in electrical contact with the cylindrical wall of'op'ening; 119, and also in heat conducting contact therewith, so that -the insert in effect formsa part of the nozzleelectrode and operates. correspondingly. as will be described subsequehay.

The insert is removable from opening 119 and-m be replaced when theamount of deterioration-- warrants it. Cap 92,'which is formed with a centraliopenin'g 123 having a substantially larger diameter than the passage] in the insert body, is recessed at 124"to'seat overthe'.

outer portionof-insert flange 122'and thus hold the in-'" sert iri. position. The cap is provided with a skirt'1'26 which is threaded over cylinder 116, and when tightened in position, maintains the cap and insert in predetermined longitudinal positions such that the lower end'of tube body/121 is-fiush with the upper wall of the cylindrical chamber 127defined byelectrodes 91 and 89.

In order to hold the elements in assembled condition, a retaining ring 128 is threaded into the depending skirt 112, so that it abutsagainst a radial wall of insulator 109 and causes flange 94 to be in close electrical contact with the lower surface of plate 89. a g

Current connection is made to the nozzle 91 bymeans of a threaded post 129 thereon (Figure 4), which post is connected to the negative lead 46 indicated in Figure 1E A" co'rre sponding post, not shown, is provided on body' 88 and is connected to the positive lead 41.

The remaining portions of the coolant circuit comprise an insulating hose 131 which is connected between passage 97 and a passage 132 in nozzle portion 111, the latter passage leading to water chamber 114. Pas-- sage 98 in body 88 is connected to the water intake hose 52, and a second passage 133, extending in nozzle portion 111 from water'chamber 114, is connected to-tlie return hose 68.

to a passage134 in electrode portion 111, such passage being tangential to thechamber 127 and lying in a plane perpendicular to the axis'of the torch. The passage terminates in an inlet opening 136which is located closely adjacent the lower surface of nozzle wall 113. Gas flowing through passage 134 and entering the chamber 127 spirals inwardly, as previously indicated, and finally flows upwardly in a spiralling motion along .the inner cylindrical wall of insert body 121 as illustrated at 137. This provides various functions previously indicated, and which will be described in detail subsequently, relative to the plasma stream 138. g

The hose or conduit 87 from the source 86 of auxiliary gas or powder is connected to the lower end of passage 99, so that gas or powder flows upwardly through opening 106 and into the plasma jet or stream 138 aspreviously indicated.

The'gas-constricted arc struck between metal electrodes, with consequent sustained, very high-temperature plasmajet (Figures 5-8) Before commencing with a detailed discussion of the methods and theory of the invention, with reference to schematic Figures 5-8, certain defects of two groups or types of known prior art torches will be indicated.

In a number of prior art torches, which may be'classi-f tied in one such" group, plasma was generated by means of an electric arc struck between'metal electrodes,- and was blown by gas through'an opening in one of the el'ec trodes. With relation to some such torches, it was claimed that the arc and plasma were surrounded by whirling gas. However, in no such torch was the are constricted. There was, therefore, nohigh current-density arc and no very high-temperature plasma stream. The useful temperatures achieved with such torches were tens of thousands of degrees lower than thoseobtainable with the present torch. The current densities in the arc were hundreds or thousands of times lower than in th present torch.

Torches in the other such prior art group incorporated a nozzle electrode formed of carbon, and aback electrode also formed ofcarbon. Whirlingfwaterwas employed to constrict thearc passing .ibetw'eensuch electfodes',-aiid cause 'assageor aplasmajerthreughnhe'nowe open? The gas inlet hose 72 from control 39 is connected 7 the maximum cooling action thereat.

ingt High current densities and temperatures were .result of rapid deterioration of the carbon nozzle. The

whirling water was not passed through the nozzle opening, and could not protect the wall of the opening fro-m deterioration. Furthermore, the plasma was greatly contaminated by vaporized carbon. Because of these and other important factors, such torches were used only experimentally and not practically or commercially.

In connection with the last-mentioned group of prior art torches, it is to be understood that the generation of .a plasma jet with carbon electrodes is very different from plasma jet generation with metal electrodes. This is largely because carbon is a poor conductor of heat and will, therefore, vaporize very rapidly at the nozzle opening to provide material which makes up the plasma stream.

This is not true of metals, especially highly conductive ones which are water cooled. An important contribution to the art made by applicants, therefore, is the provision of apparatus and methods which will maintain high current-density plasma streams with metal electrodes, and without resulting in undesirably fast burning or deterioration of such electrodes.

Referring now to schematic Figure 5, an elongated base or back electrode is indicated at 141. The nozzle is indicated at 142 and has an opening 143. Current is applied to the base and nozzle through leads 144 and 145, respectively, and may result under proper conditions in generation of a plasma jet 146. As thus far described, Figure generally indicates not only certain basic components of the present torch, but also some of the prior art torches referred to above. The indicated electrical polarity, however, is an important feature of the present invention. Such polarity, with the nozzle negative, will be discussed under the next sub-heading.

Schematic Figure 6 illustrates a feature of the invention whereby the small-diameter, relatively long elements of Figure 5 are made large in diameter and relatively short or thin (in comparison to their diameters). This is to accommodate the enormous currents present in the torch. More specifically, the nozzle 147 of Figure 6 is illustrated as being a relatively large-diameter disc as compared to the ring 142 shown in Figure 5, and the plate (base or back electrode) 148 is also of large diameter and is.a relatively thin disc as distinguished from the elongated cylinder 141 shown in Figure 5. A great advantage of this electrode construction is that the current connections may be of large area and made about .the peripheries of the plate and nozzle, so that the electrons flow radially (instead of axially) to concentrate at the central nozzle opening 149 and the adjacent plate surface, as indicated by the arrows 151. These arrows 151 indicate the electron flow directions, opposite to conventional current flow directions, which (with the above-described current connections shown by the polarity signs) are seen to be radially inwardly toward the nozzle opening 149, and radially outwardly from the center of plate 148. The described arrangement greatly reduces the heating (both resistance heating and contact heating) at points remote from the jet, where heating is not desired, and results in greater torch etficiency and in other advantages. The electrodes are formed of highly conductive metal, such as copper.

Referring next to Figure 7, the construction is generally the same as that shown in Figure 6 except that the nozzle 152 and plate 153 are made somewhat thicker so that water chambers 154 and 155, respectively, may

be formed therein. The water inlet to nozzle chamber 154 is indicated at 156, and the outlet 157 is shown as being diametrically opposite thereto. The plate water inlet 158 is axial, so that the coolest water impinges directly against the center of the upper plate wall to provide Thereafter, the

162 and then out an outlet opening 163.

Plate is shown in Figure 8 as having a frustoconical wall 164 which is coaxial with the nozzle opening. Such wall terminates, adjacent the nozzle opening, in a round radial surface into which is inset (such as by casting) a cylindrical block 165 of a refractory metal such as tungsten. The block 165 is shown as protruding above the plate body into which it is inset, and as having a beveled annular edge 166 which is coaxial with the nozzle opening and has a somewhat larger diameter. The plate construction shown in Figure 8 may be considered as being correspondingly present in views such as Figures 2, 3, 8A, 9, 19, 18, 19, 20, 21, and 22.

An annular gas or nozzle chamber 168 is shown in Figure 8 as being defined between the plate and nozzle, and coaxial with the nozzle opening, by a metal ring 169, there being an insulating gasket 170 provided between such ring and the plate. Gasket 170 is flush with the lower edge of plate wall 164. Gas is intro duced into the chamber 168, preferably at a point adjacent the under surface of nozzle 152, through a tangential passage 171 and inlet 172 corresponding to the passage 134 and inlet 136 illustrated in Figure 4. The gas flow is from the source 69 (Figure 1), either directly or through the control 39, and the tangential relationship causes the gas to whirl or spiral around the cylindrical chamber 168 in the vortical action mentioned in connection with Figures 24. The result is that the entire chamber 168 is filled with gas, as shown, except for a cylindrical passage or chamber (vortex) at the axis of the chamber 168 and through which the arc and plasma jet pass as indicated at 173. The whirling gas which surrounds the jet 173 flows, in a whirling or vortical action, outwardly (upwardly) through the nozzle opening 1'74. It is to be understood that the plasma jet 173 is in large part made up of very hot neutral gas (as well as ions and electrons) drawn from the wall of the vortex. The water cooling means, and the electrical connections, are the same in Figure 8 as described with relation to Figures 5-7.

The plate construction shown in Figure 8 provides a number of advantages relative to gas fiow, arc stability, electrode life, etc. Since the outer surface of the refractory block 165 is closed to the nozzle than are other portions of the plate, along fmstoconical wall 164, an additional factor is provided causing the arc to remain in contact with block 165 and not with non-refractory portions of the plate. This produces, in combination with other important factors stated elsewhere in this specification, a highly stable arc and plasma jet.

It is pointed out that the outer surface of the block 165 is located close to the nozzle, the spacing therebetween being shown as less than the diameter of nozzle opening 174. This also is a factor tending to produce a highly stable arc, and minimized electrode deteriorathe inner nozzle edge defining the nozzle opening, such edge being grounded or beveled as stated hereinafter. The result of such gas flow is that the arc is stable and properly constricted. Furthermore,- when the proper electrical polarity is employed (as stated below) the vortex.

(a) Dynamically constricting the arcand plasma 173;

(b) Eifecting such constriction efficiently;

(c) Protecting of the work from oxidation, and

(d) Protecting the electrodes (particularly the nozzle) from rapid deterioration.

the vortex or are passage, is not appreciably ionized and,

therefore, does not cnduct electricity. Since the gas acts .as an electrical insulator, it follows that the arc and plasma 173 must fiow through the cylindrical vortex at the axis or center of the chamber. The resulting constriction of the are means that increased currents will produce increased temperatures, instead of merely increasing the cross-sectional area of the arc and plasma as would occur if there were no constriction.

Constriction of the arc is further achieved by a phenomenon which may be termed thermal pinc Thermal pinch takes place because the relatively dense and cool gas in chamber 168 effects cooling of the outer or peripheral regions of the plasma. This lowers ionization and conductivity in such outer regions, with the result that the current concentrates at the center or axis of the vortex. At very high currents (on the order of 2,000 amperes), another phenomenon becomes appreciable and aids in constriction of the arc. This last-mentioned phenomenon is a magnetohydrodynamic effect which may be termed magnetic pinch.

In order to achieve a satisfactory gas density in chamber 168, to thus effect are constriction as above stated, the absolute gas pressure at inlet 172 should be at least 1.6 times the absolute ambient pressure (outside the nozzle opening). Thus, where the torch is employed under atmospheric pressure, the gas pressure at inlet 172 should be, at least about 9 p.s.i. gauge. It is preferred that the gas pressure at inlet 172 be higher, for example 75 p.s.i. gauge, the normal working range being between 9 p.s.i. gauge and 200 p.s.i. gauge when the torch is employed under atmospheric pressure. Such' gas pressures are substantially uniform longitudinally and circumferentially of the torch within chamber 168, along the interior wall of ring 169.

Throughout this specification and claims, the gas pres sure at the inlet 172, and similar phrases, denote the pressure at such inlet but'within chamber 168, after any initial expansion through the inlet opening.

Not only should the gas inlet pressure be relatively high, but the gas pressure gradient adjacent the vortex should be steep. Ideally, the gas pressure in chamber 168 should drop abruptly to about zero gauge at the This would produce a perfectly defined gas 'wall around the vortex. Although such perfect definition of the gas wall around the vortex or are passage is notpractical-or possible, good definition is achieved by the following empirical method A manometer-probe is inserted 'into chamber 168 and employed to sample the pressure at various radial positions. Such factors as the diameters of the inlet and outlet openings 172 and 174 are increase in pressure also reduces the diameter of the vortex and further constricts the arc and plasma.

Function (b), effecting arc constriction in a relatively efficient manner, is achieved because gas is employed instead of water, for example. It is stated above that the whirling gas in chamber 168 is relatively cool. The term relatively is employed because the gas is actually quite hot although it is much cooler than the arc or plasma. The gas temperature near the plasma in chamber 168, and along the wall of nozzle opening 174, may be on the order of 3,000 F. Such gas may nevertheless perform the above-stated function of constricting the arc, and the function of protecting the electrodes from rapid deterioration'as will be described below.

It will be understood that the passing of such heated gas through the nozzle opening adds to the useful heat external to the torch. This is in contrast to the type of prior-art torch in which whirling water was employed to constrict the arc, since such water was returned to a drain. The heat in the bulk of the water was thus wasted, although it is appreciated that some of the water turned to steam and thus passed out the nozzle opening.

In order to achieve the desired torch efficiency, and other beneficial results, the diameter of chamber 168 should be made at least twice the diameter of nozzle opening 174 at its narrowest point. This prevents excessive cooling of the gas near the plasma, and the plasma itself, by the electrode cooling Water. It follows that the amount of heat lost in the electrode (and casing) cooling water is minimized, and the amount of heat which passes through the nozzle opening is a maximum. It is to be remembered that for most purposes the heat inside the torch is not important, the desired result beingto create maximum heat in the external plasma jet.

Function (0), protecting or shielding the work from oxidation, is achieved by employing an oxidation-preventing (preferably inert or noble) gas to effect are constriction, and passing such gas through the nozzle opening. The noble gas surrounds the external plasma jet at the point where the pet impinges against the work, thereby shielding the work from. oxidation. The shielding is effected without undesirably cooling the work, since the noble gas is heated in the torch as set forth above. It is noble gases) is very detrimental to the metal (such as tungsten) electrodes.

Function (0!), that of protecting the electrodes from rapid deterioration, is achieved by employing an oxidation-preventing (preferably noble or inert) gas as the above-described arc-constricting gas in chamber 168, a

and passing such gas through nozzle opening 174. The electrical polarity is also important in this connection, as will be described under the next sub-heading. The wall of opening 174 is thus protected by the gas, such gas being relatively nonionized because of its rapid flow and because of the Water cooling of the nozzle. Since the nozzle opening wall is protected by nonionized gas, it follows that the arc is caused to pass through the opening 174 along with the plasma. The arc therefore enters the nozzle at the nozzle region, indicated at 176, relatively remote from the plate. Reentry may occur at region 176 because the gas, in expanding through the nozzle opening, diffuses at the upper nozzle portion and thus may become sufficiently ionized to conduct the arc.

By way of definition of terms, it may be stated that the arc is made up of those ions and electrons which pass between the nozzle and plate, and form part of the electric circuit. The plasma, on the other hand, may

amass 13 be defined as those ions and electrons (plus heated neutral gas) which stream or jet upwardly from the plate and outwardly through the nozzle to the region indicated at the extreme upper part of Figure 8.

To amplify upon the above description of function (d) performed by the gas, the striking of the are at nozzle region 176, and not at the nozzle region surrounding the lower end of opening orpassage 174, effects the following desired results. In the first place, the plasma jet, which is arrincident to the arc, is necessarily caused to flow through the nozzle opening 174 and outside the torch where it can perform useful work, this in contrast to situations in which the arc and jet are completely confined inside of the chamber 168. In the second place, the striking of the arc in the region 176 results in preservation of the smoothness and perfection of the cylindrical wall of opening 174, as well as of the under surface of nozzle 152, by preventing oxidation and the formation of pits which would cause turbulence in the whirling gas flow and consequent reduction in the insulating and protective action performed by the gas. In the third place, the striking of the arc in region 176, or at least at points spaced above the lower end of the nozzle opening, is important to the maintenance of a constriction of predetermined size, this in contrast to constructions in which the constriction becomes increasingly larger due to a'bur ning and eroding action, which enlargement of the constriction reduces the temperature of the plasma jet for a given power input to the torch. In the fourth place, the portion of the arc outside the torch adds to the external, useful heat. The whirling gas around the jet 173 in opening 174, and also in chamber 168, provides a cooling action which cooperates with the action of the water in chambers 154 and 162 to prevent rapid deterioration of the electrodes and excessive heating of the torch.

,It is pointed out that the above actions are interdependent or cumulative. If substantial and continued arcing occurs at the nozzle region surrounding the nozzle opening and adjacent the plate, instead of relatively remote therefrom, such region will become highly pitted and eroded. When the polarity of the nozzle is positive, the pitting and erosion will then become progressively greater until the constriction diameter is enlarged excessively, or until the plasma no longer passes through the nozzle but instead remains inside the torch.

The nozzle region surrounding the nozzle opening, and adjacent the back electrode, should be rounded or beveled, for example as shown in Figure 12 or at x in Figure 8. This being the case, the bevel x in Figure 8 may be considered as being correspondingly present in views such as are shown in Figures 3, 10, 11, 14, l5, 16, 20, 21, 22, 23 and 24. The purpose of eliminating the sharp edge at the inner end of the nozzle opening is to maintain a relatively smooth, turbulence-free gas flow out the openingwithout creating any shock or choke efiects.

This aids the relatively inexperienced operator in effecting proper initial operation of the torch, in such manner that the arc passes through the nozzle opening.

It is to be understood that an experienced operator may (such as by using a relatively high current) substantially immediately cause the arc to pass through the nozzle opening of the torch, even though the inner end of the opening is initially defined by a relatively sharp edge. Even an inexperienced operator may cause the arc to pass through the nozzle opening after such a torch has operated a short period of time, such as five or ten minutes. The latter is because the sharp inner edge of the nozzle, around the nozzle opening, is burned away during the initial operating period, to result in abeveled edge. Thereafter, assuming the nozzle is of negative polarity and the gas flow conditions are proper, the arc will pass through the opening and operation may be continued for hours.

i4 Advantages of making the nozzle negative (Figures 8, 8A, 8B, 8C and 8D) The passing of the are (not merely the plasma) through the nozzle opening 174, or at least into such opening until substantially all terminal portions of the are are spaced from the under (inner) surface of the nozzle, is not only dependent upon the gas but also upon the electrical polarity employed. Stated otherwise, the gas flow through inlet 172 and out nozzle opening 174 cooperates with the preferred electrical polarity to produce the very desirable results stated under function (d) of the previous sub-heading. Such preferred electrical polarity, as previously indicated, comprises making the nozzle negative and the plate (back or base electrode) positive.

So far as is known to applicants, all prior art workers made the plate negative and the nozzle positive, or else employed alternating current. The advantages of making the nozzle negative were not appreciated. Some prior art workers claimed to blow the are through an opening in one of the electrodes, but this was in reference to low-current arcs which were not constricted. The present arc, having a very high current density, is extremely stable and is made up of ions and electrons moving at very high velocities. The present are is, therefore, not readily susceptible to being blown by the gas, and (in experiments to date) will not pass through the nozzle opening unless the indicated electrical polarity is 0 employed.

5 to Figure 8A, wherein the nozzle is negative as desired,

the electric arc is indicated at a. This View shows a nozzle (like that of Figure 8) after substantial use. The pitting or eroding action caused by the arc is, as illustrated at p, substantially confined to the nozzle region surrounding the nozzle opening and relatively remote from the plate. This leaves the portion of the nozzle opening wall adjacent the plate, indicated at c, in its original condition so that it will effect uniform constriction of the are a passing through the opening. Stated otherwise, since portion c remains perfect, the diameter of the vortex or passage through the gas, and through which the arc passes, remains uniform (for a given gas flow rate) and results in uniform constriction of the are even after long use of the torch.

Referring next to Figures 8B and 8C, it has been found, in experiments to date, that the illustrated conditions of the are a normally occur when the nozzle is positive and the plate negative. Figure 8B shows the arcing with a new nozzle electrode, and Figure 8C shows the condition of the arc and the same nozzle electrode after a substantial period of use. The are a is seen to emanate from the wall of the nozzle opening at points adjacent the plate, and despite the described insulation effects produced by the gas. This (Figure results in pitting and erosion at q, and causes the arc to fan out or diverge upwardly. It may thus be seen that the arc is no longer constricted to its original diameter (Figure 8B) but instead has a larger diameter (Figure 8C) which reduces the temperature of the arc for a given power input.

Figure 8D illustrates the extremely bad condition in which the arc does not enter the nozzle opening. Under such circumstances, which may occur when the nozzle is positive or when the gas flow is improper, the torch merely burns or melts while producing little or no desirable resultsi The preferred negative polarity of the nozzle (Figures '8 and 8A) is highly important in at least one other regard. With such polarity, the temperature of the plasma jet is very greatly increased as compared to situations in which the nozzle is positive (Figure 8C). The temperature increase is sometimes on the order of 50%.. Regarding the theory of such increased temperature when the nozzle is negative, it is applicants belief that the momentum of ions in the plasma jet is considerably higher, and that of electrons lower, as compared to situations in which the nozzle is positive. It follows that a greater temperature will result in theplasma jet because of the greater momentum thereof and consequent release of increased kinetic energy when the jet impinges against the work. Furthermore, when the nozzle is negative a portion of the arc is outside the torch where it produces available and useful heat.

As previously indicated, it is not always necessary that the arc extend clear to the outer surface of the nozzle. The basic concept is that there should be a substantial portion of the wall of the nozzle opening, relatively adjacent the plate or back electrode, which is free of arcing. This can occur even though arcing occurs from portions of the nozzle opening wall relatively remote from the plate.

Description of such factors as ranges of voltage and currrent, etc.

Stated generally, the present torch is a high-current, low-voltage device. It is not to be confused with torches in which a high voltage is impressed between two electrodes in order to cause passage of a low-current (and low-current density) arc therebetween. I

The currents for a normal size torch, constructed in accordance with the present invention, range between 20 amperes and 2,000 amperes. It is to be understood, however, that very large torches may employ higher currents, and that very small torches may employ lower ones, down to amps, or even less.

The normal voltage range in the present torch is between 20 volts and 500 volts, but again there may be exceptions for torches of unusual size.

The distance between plate and nozzle, at the nozzle opening, should be small. Stated generally, the spacing between the plate and nozzle, at the nozzle opening, should be about 0.3 to 2 times the diameter of the nozzle opening at its narrowest (most constricted) point. The plate-nozzle spacing (at the nozzle opening) should not be more than 4 times-the minimum diameter of the nozzle opening.

The normal range of minimum diameters of the nozzle opening is & inch to 1 inch. This same normal range applies to spacing between plate and nozzle, at the nozzle opening. As before there are exceptions, such as in the case of monstrously large torches for special purposes.

The normal over-all diameter of a commercial torch is between one and ten inches. Such diameter, in eachinstance, is normally substantially greater than the length or axial dimension of the torch (excluding the handle).

The cross-sectional area of the nozzle opening at its most constricted point is governed largely by the desired power input to the torch, but also varies widely in accordance with a number of otherfactors. Stated generally, however, such area and the power input are directly proportional. For example, where the opening diameter is & inch the power input. may be one kilo- Watt. For a 4 inch opening diameter the power input may be fourkilowatts, and for a /4 inch diameter opening the power input may be on the order of 64 kilowatts.

-These opening diameters, and power inputs, are representative for torches such as may be used for cutting, etc.

The amount of arc constriction obtainable with the present torch is very great. For example, 500 amperes of current have been passed through a nozzle opening less than ,4 inch in diameter. Itmay thus be understood that enormously high temperatures (5,000? F,-

30,000 F.) are achieved.

not important, and a special composition of plasma is.

desired.

The gas pressure in the arc chamber has been discussed previously, in connection with are constriction. The rate of tangential or vertical gas flow varies widely in accordance with pressure requirements, and in accordance with other factors. The rate of tangential flow should not be so high as to prevent striking or maintenance of the arc, but should be sufliciently high to produce arc constriction and the other actions or effects previously indicated. Also, since argon and similar gases are relatively expensive, the gas flow should not be higher than necessary. It has been found, with a torch of the type shown in Figures 3 and 4 and having an outer diameter on the order of one to four inches, and properly sized chambers and passages, that a gas flow through passsage 134 (Figure 4) of approximately 50 cubic feet per hour is satisfactory. The range is quite great, however, and many other gas flow rates (such as 36 cubic feet per hour) may be satisfactory. Such values produce a relatively rapid gas flow, such as 117 feet per second, and consequent vortical action. 7

The gas inlet, such as is indicated at 136 in Figure 4, is preferably relatively small in a torch of the size indicated. The diameter of such gas inlet should be less than the diameter of the nozzle opening at its narrowest (most constricted) point, and is preferably about /2 such minimum diameter of the nozzle opening. The exact'relationship is, however, determined emperically as previously stated. Typical diameters of the gas inlet, for a torch of the general size stated, range from ,6 inch to /2 inch.

The following is a table of currents, voltages, and gas inlet pressures for a typical torch in which argon is employed as the whirling gas, the plate-nozzle distance being 4 inch:

Pressure at the Gas Inlet Voltage as Opening 136 in Figure 4 (p.s.i. gauge) Pressure at the Gas Inlet Opening, Such as Opening 136 in Figure 4 (p.s.i. gauge) Current (Amperes) Voltage (Volts) These tables illustrate not only the high currents in comparison to the voltages, butalso thegreat effect gas voltage.

Opening, Such ace-2,869

17 Additional theory and methods relative to the plasma jet torch (Figures 8, 9, and

The length of the plasma jet, and certain other characteristics thereof, may be controlled by regulating the quantity of gas introduced tangentially into the arc chamber through inlet 136 (Figure 4), for example. Thus, where the rate of tangential gas flow is high there is a relatively great electrical insulating effect in the arc chamber and around the nozzle opening, and a relatively great choking eflect. This results in a lower-current are, for a given electrical power input, than in cases where the tangential gas flow is in lesser quantity. It is primarily for this purpose that the gas flow and electrical input are both passed though the control 39 indicated in Figure 1, which control operates to regulate and stabilize both electricity and gas flow to produce the type and size of plasma jet which 'is desired.

To amplify upon the preceding paragraph, let it be assumed that the initial gas flow rate is relatively low, that the initial current is 200 amps, and that the initial voltage is 30 volts. Because of the relatively low gas flow rate, the gas or arc passage (vortex) diameter will be relatively large, and the plasma jet will be relatively short and fat. When the gas flow rate is increased, the vortex diameter is lessened to further constrict the arc and make the plasma jet longer and thinner. Because of this choking action, the voltage value necessary to produce the 200 amp. current will increase'to 100 volts, for example. Much more electrical power is therefore required, to pro duce a given current value, when the gas flow rate is high than when the gas flow rate is low. However, the additional constriction of the arc increases the current density, and thus the temperature of the arc and plasma.

It has been found that the location of the tangenital gas inlet 172 (Figure 8), and the electrical potential of the gas when introduced through such inlet, are of im portance. The gas which flows through the inlet 172 tends, for reasons unknown to applicant, to result in an electrical discharge therearound unless the electrical potential of the gas, and the gas inlet location, are properly selected as will next be described. Such an electrical discharge may produce burning of the insulation, loss of power, and pitting or erosion of the electrodes.

It has been discovered that the incoming gas passage 171 should be through a good electrical conductor which is electrically associated with the nozzle 152 and is at the same electrical potential, such as ring 169 in Figure 8. Also, the gas inlet 172 should be located closely adjacent the under surface of nozzle 152, that is to say the upper wall of chamber 168.

With relation to the reasons why the relationships described in the preceding paragraph minimize or eliminate undesired electrical discharge within the torch, it should be understood that the electrical potential of the plasma jet 173 at the lower end of opening 174 is substantially the same as that of the nozzle. Accordingly, since the incoming gas is also at the potential of the nozzle, there is little or no potential difierence between the gas inlet and the plasma jet at the nozzle, and little or no electrical discharge therebetween. The potential of the plasma jet becomes nearer to that of the plate as the plate is approached. However, portions of the plasma jet nearer the plate are farther from the gas inlet opening 172, and this increased distance compensates for the increased potential difference to maintain electrical discharge at a minimum. There is also minimum electrical discharge between the inlet 172 and plate 167, since the inlet is located as far as possible from the plate. The problem of undesired electrical discharge through the gas in chamber 168 has not been found to be serious except in the region of the inlet .172.

Referring now to Figure 9, the nozzle is constructed substantially the same as in Figures 7 and 8, and has been given the same reference numerals. The plate is indicated at 177, and has an axial water inlet 178 to the water chamber 179, and a downwardly extending outlet 181 therefrom. A casing or jacket for the electrodes is schematically indicated at 182, and has water passages 183 therethrough. Such water passages may communicate with water chambers in the casing, such as those indicated at 63 and 64 in Figure 2. A tangential gas inlet passage 184 is shown as extending through the easing or jacket, and corresponds to the passage 134 shown in Figure 4.

A hose 185, formed of electrically insulating material and corresponding to the hoses 62 and 131 previously described, is connected from outlet 181 to a water passage 183 in jacket 182, and thus to the water chamber within the jacket. The water then flows through a tube 186 to water chamber 154 in the nozzle, and thence through an outlet passage 187 to a drain or to the water source 51.

The insulating hose provides a relatively long electrically insulating path between the plate and nozzle, so that the amount of current flow through the water between the plate and nozzle is extremely small. If there were a direct, parallel water connection between plate and nozzle, a substantial amount of current would flow therethrough, resulting in power losses and also in electrolysis. Such electrolysis may result in the generation of hydrogen, and consequent danger of explosion. These defects may also be eliminated by providing two completely separate water circuits from the water source to the nozzle and plate, but this necmsitates the use of four separate water hoses and results in inconvenience and expense.

The described water circuit results in cooling not only of the nozzle and plate, but also of the jacket 182 and thus the periphery of the torch. This is important since the temperatures generated in the plasma jet are so high that the torch periphery might become so hot as to be unmanageable if no water cooling means were employed.

, Because of the extremely high temperatures generated n the arc and plasma jet, the problem of water sealing 1s acute. It has been found that if water leaks into the nozzle opening the arc will be extinguished. However, seals such as 0-rings should not be placed close to the nozzle opening, or to the center of the plate, since they would immediately burn or'boil. It follows that the seals should be spaced a substantial distance from the plasma jet, with water cooling elementsiuterposed therebetween as'shown in Figure 2, for example. Not-only should the seals be spaced from the jet, but conventional electrical insulating elements should also be so spaced. Thus, the inner diameters of insulating elements 27 and 108 (Figures 2 and 3) are made relatively large in order A that such elements will be spaced from the 'baseof the plasma jet. A synthetic such as Teflon (tetrafluoroethylene) has been found to be a suitable electrical insulator, but other insulators (such as ceramics) maybe employed.

it is emphasized that the water, or other coolant, should be brought close to the nozzle opening and to the center (arcing portion) of the plate, to prevent burning of the electrodes and to minimize deterioration thereof. N0 heat-insulating elements should be interposed between the water chambers and the arcing portions of the electrodes. The temperature gradients, where the electrodes are water cooled as indicated, are very steep and may be thousands of degrees per millimeter.

The coolant is not necessarily water, although water is most satisfactory in a majority of situations. In some situations it is desirable to use gas, instead of water, as the cooling medium in chambers 154 and 179. As previously indicated, the whirling gas in the described torches cooperates with the water in producing cooling efiects.

Referring next to Figure 10, the plate is schematically represented at 188 and has a water chamber'189 therein. Water is introduced axially into chamber 189 through r 19. a large diameterpip'e' 191, and an auxiliary substance may be'introfducedthrough a pipe 192- which extends axially "of pipe191 andi terminates in an opening'193 in the center of the plate. The nozzle is represented at '194a'sfhaving a water chamber 196, andthe casing or the plate is from inlet pipe 191'into the'wat'er chamber 189,"'andthence radially through outlet 203 and to the drain. The plate and nozzle water circuits may, if desired, be 'asso'ciated'with each other' as described above.

A cap is designated by the number 204, and'r'nay correspond to the cap 7 shown in'Figure' 2. An' opening 206 is provided in the cap above the nozzl'e'opening 207, being of substantially larger diameter than the nozzle *opening which, in turn,'i's' normally of larger diameter "than the auxlliary inletl93 These three openings are coaxial, as are the electrodes. i i

A tangential gas inlet flow'is indicated by the arrow 208, being the same as that effected through pas sage 134 and inlet 136 shown in Figure 4. Gas flow between cap 204 and nozzle 194is indicated 'by the arrows 209 and "is the same as that effected through passage 73 and inlet 76 shown in Figure 2A. Such gas flow between cap 204 'andthe nozzle may, however, be radial or axial instead of vortical in certain instances. In contrast to the show- :ing of Figures and 2B, the gas flows 208 and 209 are l independent of' each other, and may be from diiferent sources.

- The gas indicated by arrows 209 is inert or oxidationpreventing, and has the beneficial effect of shielding the work from oxidation. Such action produced by the gas flow 209 augments, in a co-operative action, the action of inert (or oxidation-preventing) gas 208 which flows upwardly through nozzle opening 207. In this connection it is pointed out that an excessive amount of gas (indicated at 208) should not be introduced into the gas or nozzle chamber, for flow out the nozzle opening 207, since the --1nsulation effect produced by the gas might then be so 5 high as to prevent striking of the arc at the upper portion of the nozzle, as indicated at 176 in Figure 8. Also,

an excessive gas flow might result in reduction of the diameter of the arc passage or vortex to such an extent that the arc' is choked off. On the other hand, the gas flow 208 should be sufliciently great to provide the described arc-constriction action, and the various other beneficial eifects stated above.

It is pointed out that the whirling of the gas indicated "at-209, and the large diameter of opening 206, maintain *such gas away from the arcing region of the nozzle. This permits the arc to be struck and maintained at points such as are indicated at 176 in Figure 8.

In addition to permitting addition of noble gas for work-protection purposes, the cap 204 permits introduction of substances into the plasma jet outside the arc chamber and passage, yet at a location such that the substances so rntroduced remain in the jet for the maximum period of time. The substances, such as powdered metal,

ceramic, ore, etc. are introduced by mixing them with. .the gas indicated at 209.

Constructions of the arcing regions of the nozzle and plate (Figures 1 1-19)- Referring next to Figures 11-19, the nozzle electrodedric-al nozzle opening 213'is illustrated and is of the type 2 shown in the majority of the figures previously described.

Figure 12 illustrates a nozzle opening having a narrow or constricted part adjacent the plate and a relatively" 20 large aiamaer" part remote from the plate. More particularly, the constriction is shown at 214 as having a generally convex :wall; whichmerges through a smooth curve with a'larg'er diameter, generally concave wall poractionwhich'prevents (under proper conditions) strik ing of an are either from surface 218 or from the wall of constriction 214. The whirling gas flowing upwardly around the wall of constriction 214' fans outwardly into concave portion 216 and becomes relatively diflused.

It follows that the arcwill strike between concave portion 216 and the plate, so that the pitting necessarily incident to arcing (especially when no refractory metal is employed) will be substantially confined to portion 216 and will not be present at constriction 214. The diameter of the constriction will therefore remain constant, and the gas flow therearound will be smoothand free of turbulence as is highly desirable for continuous and practical operation of the torch. l Y

a. Figure 13 illustrates a nozzle opening in which the constriction 219 is spaced above the lower nozzle sur face 221 (the surface closest to the plate). The portion 222 of the opening, below construction 219, is short and diverges downwardly in a relatively steep manner.- By contrast, the portion 223' above the constriction is longer, and more gradual in divergence angle; This construction, which is known as aLaval-nozzle, is particularly the diffusing gas does not provide sufiicient electrical insulation to prevent striking of the arc. Thus, the arc is struck between the plate and the wall of portion 223, as is desirable in order to maintain the constriction diameter constant, and insure that the plasma jet passes through thenozzle opening. In some cases the arc may pass all the way through the 'nozzle opening, and strike on the'upper surface of the nozzle.

- Figure 14 illustratesa cylindrical opening 224 which is partially defined by a ring 226 of electrically conductive refractory substance, the "ring being inset in an annular channel 227 at the upper end of the opening (remote from the plate). The refractory ring 226 is preferably composed of a metal such as tungsten, tantalum, cadmium, and the like. The-metal '226 is preferably in intimate contact with the base metal in order that the heat and electrical conductivity will be at a maximum, it

having been found that application of the refractory metal by casting or plating is preferred. .Because of its refracv of the nozzle.

. tory substance on the negative electrode (cathode). This the plate as previously indicated, thus prolonging the life Thoriated tungsten is desirable .to employ as the refracis because the resultant increase in electron emission from the cathode produces desirable efiects,'such as in stabilizingthe arc. J a

: Figure 15 shows a construction which is the same as Figure 14 except that an additional ring 228 of refractory J metal is inset 'at the lower end of nozzle opening 224,

in'fsuch mannerthat it extends radially inwardly to providea relatively small diameter opening'229 and a shoulder 231thereabove, The gas in the nozzle chamber longed through use of an insert such as the thus flows upwardly through opening 229,, which comprises the constriction, and diffuses around shoulder23 1.

It follows that an arc will be struck between shoulder 231 and plate. However, it has been foundthat addiitional arcingmay occur between the upper-portion of the nozzle and,,the plate, the effects ofsuch arcing being minimized due to the presence ofrefractory metal 226. Figure 16 illustrates a construction in which the entire nozzle opening. Wall is protected by providing; a short cylinder, 232formed of the refractory metal. Cylinder 232 is closely mounted in a cylindrical opening in the base metal of the nozzle, for exampleby. casting Figure 17 illustratesa construction which is-generally the same as that shown in Figure 13, excep t ;that refractory metal 233 is provided over the base metal at the wall of the nozzle opening. The function of this embodiment is the same as was described with relation to the embodiment shown in Figure 13, except that the life of the nozzle is prolonged. The nozzle opening construction shown in Figure 17 is the same as that illustrated in Figure 2. q

It is pointed out that the nozzle life may also be proone described in connection with Figure 3. Such an insert may be formed of inexpensive metal such as copper, being extremely economical and easily replaced. When the insert is positioned in its nozzle opening (number119 in Figure 3), it is preferably a loose fit. This is because the insert expands greatly when heated, as compared to the water-cooled nozzle body, and is thus caused to be (even though initially loose) in intimate heat conducting and electricity conducting contact with the nozzle'body during operation of the torch. It has been found that in situations where a cold insert is sufliciently large to be in close contact with the nozzle body, it expands so much during operation of theftorch that the opening 119 in the body is enlarged. Such enlargement is sufiiciently great that the insert will be freely removable from the nozzle opening 119 after the torch is cooled, even in situations where a pressing operation was initially re quired to introduce the cold insert into the opening.

Figures 18 and 19 illustrate the use of refractory metal in connection with the plate 212. In Figure 18, the metal is indicated at 234 as inset in a plate which does not have a hole for introduction of auxiliary substance. Figure 19, on the other hand, shows the refractory metal 236 (corresponding to the metal indicated at 31 and 107 in Figures 2 and 3, respectively) as inset around the opening 238 through which the auxiliary substance is introduced.

Additional embodiments, particularly relating to nozzle and plate constructions. (Figures 20-24) Referring next to Figures 20-24, there are schematically illustrated various additional embodiments of the nozzle, plate and related torch components Figure 20 illustrates a construction in which the nozzle comprises upper and lower spaced parallel discs 239 and 241, respectively. The discs are integrally connected at their open centers by a short hollow cylinder 242, so that a cylindrical nozzle opening 243 is formed. Upper disc 239 (the disc remote from the plate) has a smaller diameter than the lower disc, and is formed with an upwardly extending peripheral flange 244 the cylindrical outer side Wall of which seats against the inner cylindrical surface of a clamping ring 246. The lower surface of the clamping ringseats on the outer portion of lower disc 241, being adapted to press the latter against a current connector ring 247 which defines the nozzle or gas chamber 248. Current connector 247 seats, in turn, on an insulating gasket 249 which rests on the upper surface of plate 250, the latter being of the previously described type having a water chamber 251 therein.

' The nozzle, the clamping ring 246 and the current connector ring 247 are all formed of a highly conductive metal such as copper, and are held in assembled condition by a suitable cap or casing element, not shown. For example, all of the described elements may be held assembled by a cap of the general type indicated at 7 on Figure 2. Current connection is made to the connector ring 247 at a point, not shown, from which current flows upwardly into disc 241 and thence radially inwardly to the nozzle opening. Current also flows through the clamping ring 246 into upper disc 239, and then to the nozzle opening. An alternate or additional current connection may, if desired, be made to ring 246 from the current source.

The water circuit is from a water inlet pipe 252 to water chamber 251, thence radially through outlet 254 to hose 256, thence through a passage 257 in ring 246 to a water chamber 258 defined between the upper and lower discs, and thence out a passage 259 to a suitable drain. A tangential gas inlet to gas or nozzle chamber 248 is indicated at 261, and auxiliary substance may be admitted through a conduit 262 terminating at an opening 263 in the plate.

Advantages of the construction of Figure 20 are that the nozzle is relatively inexpensive to manufacture and replace, and has good electrical contact with ring 2 47 along large area interfaces 264 in which there need be no seals. O-ring seals 265 are, however, provided in the surfaces of clamping ring 246 which abut the nozzle element.

Figure 21 shows a nozzle construction which is somewhat similar to that shown in Figure 2, but is much cheaper to replace or interchange when necessary. Spaced parallel nozzle discs 266 and 267 are again provided, but in this instance the'larger diameter disc 267 is uppermost. Discs 266 and 267 are integrally associated by a short hollow cylinder 269, so that a cylindrical nozzle opening 270 is formed. The peripheral portions of the discs 267 and 266 rest, respectively, on the upper ends or rims of concentric walls or cylinders 271 and 272 which are radially spaced and connected at their bottoms by a radial wall 273. O-rings 274 and 276 are provided in the upper ends of the walls 271 and 272, respectively, in order to prevent leakage of water from the water chamber 277.

The plate 278 comprises asingle disc of metal having a downwardly extending stem 279, the latter being provided with an axial passage 281 for introduction of auxiliary substance. The peripheral portion of plate 278 rests upon the rim 282 of a cup 283, and the stem 279 is inserted through a central opening in the bottom wall of the cup. O-rings 284 and 285 are provided, respectively, around the rim 282 and around the opening in the cup bottom wall in order to prevent leakage of water from the cup. With the described construction of plate 278, the cost of manufacturing and replacing the same is minimized.

The water circuit comprises an inlet 286 in the bottom wall of cup 283, and located midway between the center of the cup and the rim 282 thereof. A water outlet 287 is correspondingly placed but in the opposite portion of the cup, being connected through an insulating tube 288 to an inlet 289 in cylinder 271. Water is thus introduced into the water chamber'277, after which it is discharged through an outlet 291 in the diametrically opposite portion of wall 271.

Gas is introduced through a tangential inlet 292 in cylinder 272 from suitable tangential passage and pipe means indicated at 293. An insulating gasket 294 is provided between plate 278 and the radial wall 273, so that there will be no leakage to the plate of current which is supplied to the outer wall 271 at a point, not shown. Such current flows through both cylinders 271 and 272 to the peripheral portions of discs 267 and 266, and thence to the region of the nozzle opening 270. Current connection to the plate is made by connecting a lead to the cup 283, from which the current flows through rim 282 to the peripheral portion of plate 278 and thence to the center thereof. A certain amount of current also flows through stem 279. All of the torch components are held in assembled relation by suitable means, not shown. Figure 22 illustrates a construction in which the nozzle 296 is a mere disc of copper or other suitable metal, and is thus extremely economical to manufacture and replace. The plate may also be a mere disc 297, or may I be provided with a stem 298 and passage 299 if it is desired to introduce 'an auxiliary substance into the plasma. V

The main elements of the torch include a body 301 which is formed as a hollow metal cylinder having an annular recess or channel 302 at, its upper central portion in order to seat the periphery of nozzle disc 296, A much larger annular recess or counterbore 303 is provided in the lower portion of body 301 in order to receive an insulating gasket 304. The outer portion of gasket 304 seats over a generally cylindrical hollow insulating element 306-, the arrangement corresponding roughly to that described in connection withFigure 3.

Insulating element 306 surrounds the plate disc '297 and also a conductive cup 307 disposed therebeneath. The cup construction is similar to that described in connection with Figure 21, there being a central opening in the cup bottom to receive stem 298, and inlet and outlet water passages 308 and 309 to permit flow of water through the cup chamber.

The means for cooling the nozzle 296 is an important feature of the embodiment shown in Figure 22, and com prises a water or nozzle ring 311 having a solid outer or body portion which seats over the upper end of body 301 and also over the peripheral portion of nozzle disc 296. A relatively thin inwardly extending flange 312 is formed integral with the solid outer portion of the ring, and terminates at its innermost edge 313 in a circle spaced radially outwardly from a tubular stem portion 314 of a cap disc 316; The lower end of such tubular stem portion 314 seats on the upper surface of nozzle disc 296 around a circle which is spaced outwardly from the nozzle opening 317. A peripheral portion of the cap disc 316 seats over the body portion of water ornozzle' ring 311, being held in position by the flange 318 'of a casing cylinder or tube 319. The casing cylinder, in turn, extends downwardly around body 301 and is held in position by a clamping ring 321 which is internally threaded therein. The inner portion of the clamping ring seats under a shoulder in insulating element 306 to maintain the cup 307, etc., in position. v

Water from a suitable source flows upwardly through an opening 322 in the clamping ring into a vertical passage 323 in body 301. The upper end of the passage 323 communicates with a passage or channel, indicated at 324, in the under surface of the outer portion of water ring 311. The passage or channel 324 communicates tan gentially with the annular chamber or channel which lies between flange 312 and the nozzle, so that water flowing through the tangential passage enters below the flange 312 in a whirling or vortical action.' As soon as such water reaches the inner edge portion 313 of flange 312 it moves upwardly and then, because of the loss in pressure and because of the continued centrifugal or whirl-.

ing action, flows radially outwardly through the annular chamber or channel which lies above flange 312. A

passage, indicated at 325 and preferably tangential, is-

provided through the body of ring 311 and serves to conduct water from the annular chamber above flange 312 to a second longitudinal passage 326 in body 301. The

passage 326 communicates through a port 327 in clamping ring 321 with a suitable drain. O-rings 323 are provided to effect the water seals, and a tangential gas inlet to the nozzle or gas chamber is provided at'329.

The are is struck between plate 297, around the upper end of passage 299, and the upper surface of nozzle 296 around opening 317, as indicated at 331. The arcing por- 24 7 tion 331 thus h econies very hot, but is" effectively cooled by the water in the annular chamber surrounding stem 'portion 314. Becauseof the described whirling action in such annular chamber, the coolant water does not flow beneath the.tube.314"and extinguish the arc, as would occur if there were no such whirling action and no O-ring or other seal at theend of stem 314. As previously indicated, it is impractical or impossible to locate a seal at such point becausethe temperature of the plasma jet is suc'h that an o-rtng or other conventional seal would boil or burn.

Referring next to Figure 23, a construction is shown in V which water cooling is provided in the absence of a solid wallbetween the water and the plasma. Instead, the Water itself forms the cylindrical side wall of the chamber in which the whirling gas is. confined. In this embodiment the nozzle is illustrated as a disc 332 having a cylindrical nozzle opening 333 therein, the opening being surrounded by' a' short hollow cylinder .334 of refractory metal, The plate comprises 'a disc 336 havinga downwardly extending axial stem 337 through which a passage 338 is formed for transmission of auxiliary substance, there being a refractory ring 339 inset around the upper end of the passage. An overhanging disc-shaped lip 341 is spaced above plate disc 336 and parallel thereto. The annular chamber between lip 341 and the plate disc 336 communicates with radial passages 342 formed in the plate. An insulating ring 343 is mounted between lip 341 and the under side of nozzle disc 332. Suitable means (not shown) are employed to maintain'the elements in assembled condition. a 6

Lip 341 has a round central opening 344 thediameter of which is substantially larger than that of nozzle opening 333. The diameter of opening 344 is also slightly greater than that of an annular recess or channel 346 provided in the under side of nozzle disc 332 around opening 333. The inner cylindrical wall of insulating ring 343 has a diameter substantially larger than the diameter of opening 344, it being understood that all of these openings and walls are co-axial. This construction results in the formation of a water chamber 347 definedby the inner surface of insulating ring 343, the under surface of nozzle 332 outwardly of channel 346, and the upper surface of lip 341. Water is introduced into suchchamber through a passage 348 which is tangential thereto and terminates in a tangential inlet opening 349. Gas is introduced into the torch through a tangential gas passage 351 terminating in an inlet 352 in the cylindrical side wall of recess or channel 346.

' With the described construction, the whirling water in annular chamber 347 flows outwardly through the largest hole, which is the round opening 344in lip 341, and is discharged radially through passages 342. A cylindrical wall of water is thus formed, being indicated at 353, and this wall 353 forms the cylindrical side wall of a' gas chamber into which gas is introduced through passage 351 and inlet 352. Such gas flows upwardly through nozzle opening 333 to provide the protective and other effects previously described. A certain amount of the gas also flows out with the water, but the quantity of gas introduced is sufficient to insure'that gas will flow through the nozzle opening. This arrangement produces cooling of both nozzle and plate with a construction in tively few seals are required. a

.Figure 24 illustrates a construction in whicha solid wall, shown as a short hollow metal cylinder or tube 354, is interposed between the gas and water. In this embodiment'the nozzle comprises a disc 355 having a nozzle opening 356 protected by refractory metal 357. The plate 358 comprises a disc having a stem 359 auxiliary substance passage 361, and refractory ring 362. Anundercut annular channel 363 is formed in the upper portion of plate disc 358 so thatan overhanging lip 364 is formed, such channel terminating at its periphery in water outlet passages 366. i

which rela- 

